Devices for closing openings in buildings and other structures

ABSTRACT

According to some embodiments, a plug or plug or insert device for use in closing an opening along an external surface of a structure comprises a main body including a first end to a second end, the main body extending from the first end to the second end along a longitudinal axis, a first surface located along the first end of the main body, wherein the first surface is perpendicular or substantially perpendicular to the longitudinal axis, a second surface located along the second end of the main body, wherein the second surface is perpendicular to the longitudinal axis, and at least one opening or feature along the first surface, wherein the first surface comprises a non-smooth finish, wherein the plug comprises a setting or a hardening material, and wherein the plug is configured to be placed within a corresponding opening of a wall.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/339,502, filed May 8, 2022, the contents of which are incorporated by reference herein.

BACKGROUND Field

This application relates generally to devices for buildings and other structures, and more specifically, to devices that are configured to at least partially plug or otherwise close openings in walls or other portions of building and other structures.

Description of the Related Art

Finished surfaces of buildings have an aesthetic value for owners and occupants of buildings. As a result, there is a need to cover any openings (or other discontinuous features) that may be created on the exposed surfaces of a building. The process of covering a hole can be time consuming, expensive and disruptive to building occupants and those performing the work. One such example is when a contractor creates a relatively small hole in the exterior of a building for inspection purposes. For instance, an opening can be created along a wall of a residential or commercial building to allow a borescope inspection tube to pass within one or more interior or otherwise hidden portions of the building. Thus, a need exists for improved devices, systems and methods for at least partially plugging or otherwise closing openings in buildings and other structures.

SUMMARY

According to some embodiments, a plug or an insert device for use in closing an opening along an external surface of a structure comprises a main body including a first end to a second end, the main body extending from the first end to the second end along a longitudinal axis, a first surface located along the first end of the main body, wherein the first surface is perpendicular or substantially perpendicular to the longitudinal axis, a second surface located along the second end of the main body, wherein the second surface is perpendicular or substantially perpendicular to the longitudinal axis, and at least one opening or feature along the first surface, wherein the first opening or feature is configured to permit a user to manipulate the plug without directly contacting the plug, wherein the first surface comprising a non-smooth finish, wherein the plug comprises a setting or a hardening material, wherein the plug is configured to be placed within a corresponding opening of a wall or other structural component of a building, and wherein the plug is configured to remain fixed within the corresponding opening using at least one adhesive.

According to some embodiments, the non-smooth finish of the first surface comprises a textured surface. In some embodiments, the textured surface comprises a stucco exterior finish. In some embodiments, the textured surface comprises a plurality of bumps, other protrusions and/or recesses.

According to some embodiments, the setting or the hardening material comprises a cement, a concrete and/or another cementitious or hardening material. In some embodiments, the main body comprises a cylindrical shape. In some embodiments, the at least one adhesive is positioned along at least one exterior surface of the plug. In some embodiments, at least one exterior surface of the plug that receives the adhesive is located along an exterior of the main body. In some embodiments, the plug is manufactured by, using and/or in a casting process.

According to some embodiments, a method of closing an opening in a wall or other member of a building or other structure comprises inserting a plug device within the opening, wherein the plug device comprises a plug device according to any of the embodiments disclosed herein or equivalents thereof. The method further comprises securing the plug device within the opening using at least one securement technology.

According to some embodiments, a method of closing an opening in a wall or other member of a building or other structure comprises inserting a plug device within the opening, wherein the plug device is shaped, sized and otherwise configured to be positioned within the opening, and securing the plug device within the opening using at least one securement technology, wherein an exposed surface of the plug device is configured to match or substantially match a surface of the wall or other member of the building or other structure immediately adjacent the opening.

According to some embodiments, the at least one securement technology comprises an adhesive positioned along an exterior surface of the plug device. In some embodiments, the opening in the wall or other member is created using a drill or other coring device. In some embodiments, the opening in the wall or other member is 0.5 to 2 inches in diameter, and wherein a diameter of the plug device is between 0.5 to 2 inches.

According to some embodiments, the opening in the wall or other member is configured to allow for a scope (e.g., borescope), other visualization tool or instrument and/or any other device, tool or instrument to be positioned therethrough. In some embodiments, the opening in the wall or other member is used for inspection purposes.

According to some embodiments, a clearance exists between the outside of the plug device and an interior of the opening in the wall or other member. In some embodiments, the plug device in inserted into the opening using a handling device. In some embodiments, the handling device comprises an elongated member that is configured to removably secure to a hole along a surface of the plug device.

According to some embodiments, the plug device comprises a cement, a concrete (e.g., expansive concrete) or another cementitious material, sand and/or other additives.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present application are described with reference to drawings of certain embodiments, which are intended to illustrate, but not to limit, the present disclosure. It is to be understood that the attached drawings are for the purpose of illustrating concepts disclosed in the present application and may not be to scale.

FIG. 1 illustrates a perspective view of one embodiment of a plug device configured to be used in a wall or other portion of a building;

FIG. 2 illustrates a schematic view of a plug device similar to the device of FIG. 1 relative to an opening in a wall of a building;

FIG. 3A illustrates a perspective view of one embodiment of a plug device configured to be used in a wall or other portion of a building;

FIG. 3B illustrates a perspective view of one embodiment of a plug device configured to be used in a wall or other portion of a building;

FIG. 3C illustrates a perspective view of one embodiment of a plug device configured to be used in a wall or other portion of a building;

FIG. 3D illustrates a perspective view of one embodiment of plug devices configured to be used in a wall or other portion of a building;

FIGS. 4 and 5 schematically illustrate perspective and side views of one embodiment of a plug device configured to be used in a wall or other portion of a building;

FIGS. 6A and 6B illustrate perspective and cross-sectional views of one embodiment of a mold device for making one or more plug devices;

FIG. 7 schematically illustrates a perspective view of a plug device with a handling device secured to the device and adhesive applied along an exterior surface of the device, according to one embodiment; and

FIGS. 8A and 8B illustrate cross-sectional and front views of a plug device secured within a wall of a building.

DETAILED DESCRIPTION

The various embodiments of a plug device disclosed herein are configured for use in the construction inspection space or construction space generally. For example, as discussed herein, the plug devices can be used to quickly and conveniently close openings in external walls or other members of a building or other structure. In some embodiments, such openings can be created in the first place as a result of inspections, such as inspections of balconies, decks and other structures susceptible to water damage (e.g., from water intrusion), seismic damage and/or the like. The openings can be sized, shaped and/or otherwise created to permit a borescope, other scope or other visualization tool or instrument to be positioned therethrough, as desired or required.

According to some embodiments, once the opening has been created and the desired inspection or other activity performed using the opening, a plug device in accordance with the configurations disclosed herein, or equivalents thereof, can be inserted into (at least partially) and be secured to the opening and adjacent portions of the wall or other member of the building or structure. In some arrangements, the plug device is secured within the opening using an adhesive and/or any other attachment method or technology, as desired or required. In some embodiments, the plug device is inserted and secured within a circular (e.g., cylindrical) opening of an external building wall such that the outer surface of the plug device is flush or substantially flush with adjacent portions of the wall or other member of the corresponding building or structure. In some embodiments, the exposed or external surface of the plug device matches or substantially matches the surface features (e.g., contour, patterns, texturing, etc.) of adjacent portions or sections of the wall or other portion of the building or structure (e.g., stucco (e.g., textured stucco, smooth stucco, etc.), other cement or mortar-based exterior surface, fiber cement siding, composite siding, vinyl siding, stone veneer, stone (e.g., natural or manmade), brick, other masonry and/or the like.

The embodiments of a plug device disclosed herein offer one or more advantages or benefits vis-à-vis existing devices, methods and/or other solutions for closing openings in external walls or other members or portions of buildings and/or other structures. For example, in some arrangements, a plug device can be inserted into an opening to seal the opening without the need to return to the site to perform additional preparatory and/or other finishing steps or procedures. For instance, in some embodiments, as discussed below, the plug can be inserted and secured to the wall or other member or portion of the building or structure in a single visit (e.g., the same visit during which the opening is created or otherwise used) without having to return (e.g., on a later day) for surfacing, grouting and/or the like. In some embodiments, once the plug is inserted and secured (e.g., using an adhesive, fasteners, etc.) to the wall or other portion of the building or structure, it can be painted. Accordingly, in such arrangements, the plug can be painted on the same day as the corresponding hole or other opening is made and the plug is secured within the opening. This can be accomplished while avoiding the need to return to the site (e.g., on a different day, a different visit, etc.) to perform any additional work on the plug and/or adjacent portions of the building. In some embodiments, the plug device can be installed into a wall or other member or portion of a building or other structure and painted (e.g., primed and painted, painted, etc.) within a particular time period (e.g., within 1 hour, within 2 hours, within 3 hours, within 4 hours, 0 to 1 hours, 0 to 2 hours, 1 to 2 hours, 0 to 3 hours, 0 to 4 hours, 2 to 3 hours, 3 to 4 hours, 4 to 5 hours, 4 to 8 hours, 4 to 10 hours, 0 to 5 hours, 0 to 10 hours, 0 to 12 hours, time periods between the foregoing values or ranges, etc.) without the need to return to the site and/or without the need to perform any additional work on the plug device.

As illustrated in FIG. 2 , a plug device or insert 10 can be sized, shaped and otherwise configured to be positioned within a corresponding opening O of a wall or other surface (e.g., exposed surface) W of a building or other structure S. In some embodiments, the insert or plug device 10 is inserted within the opening O in a direction perpendicular or substantially perpendicular to the exterior wall surface (e.g., generally denoted by arrow I in FIG. 2 ). The wall or other portion or surface W of the structure S can be a vertical or substantially vertical wall (e.g., as depicted in FIG. 2 ). However, the wall W with the opening O into which a plug device or insert 10 can be inserted and secured can include a horizontal wall, diagonal or angled (e.g., relative to horizontal and/or vertical) and/or any other orientation or design. In some embodiments, any of the plug devices 10 disclosed herein or equivalents thereof can be configured to be inserted in interior walls or elements, such as, for example, drywall, doors, cabinets and/or other structural or non-structural components or elements.

The plug device 10 can provide a fast and simple solution to closing holes or other openings created in exterior walls or other surfaces of a building or other structure. As noted above, such openings can be created for one or more reasons during and/or following the completion of the construction of a structure. For example, such holes or other openings can be created for inspection of an interior portion or areas of a structure (e.g., for possible water or other structural damage, for termite damage or other damages caused by insects or other pests, etc.), for at least temporarily securing scaffolding or another structure or system to the building and/or the like. In some embodiments, the openings are made or created by drilling or otherwise boring (e.g., completely, partially) through a wall or other surface (e.g., exposed surface) of a building or other structure. Thus, the openings can include a cylindrical shape (e.g., having a circular cross-sectional shape). Accordingly, the plug device can include a corresponding cylindrical shape that is sized to fit within the corresponding opening.

In some embodiments, the plug devices 10 are manufactured or otherwise produced in one or more standard shapes or sizes according to the shapes and sizes of the holes, openings or other orifices into which the plug devices are configured to be positioned and secured. As discussed in greater detail herein, the plugs or plug devices can comprise at least one cementitious material and/or other materials that are configured to set over time. For example, the plugs can comprise cement, sand, other aggregate, color, other fillers and/or additives and/or the like, as desired or required.

In some arrangements, the plug devices 10 are cast or molded (e.g., in a mold or similar device) or can otherwise be manufactured in advance of the creation (e.g., or existence) of the opening O in the structure. However, any other method of manufacture can be used to produce the plug devices. In some arrangements, the plug device 10 is used to close holes or other openings in structures relatively quickly and easily. For instance, in some arrangements, the plugs 10 can allow a user to create an opening and close it on the same day or visit (e.g., in one day, in less than one day, within 0 to 10 hours, etc.).

According to some embodiments, the face or surface of the plug devices include a textured, patterned and/or other non-smooth surface. The textured surface can be designed and otherwise configured to match (e.g., approximately, substantially, etc.) the surface finish of the adjacent portions or surfaces of the structure. For instance, the textured surface of the plug device 10 can include a stucco-like or similar pattern (e.g., traditional stucco, textured or roughened stucco, smooth stucco, etc.). In other embodiments, the textured or exposed surface of the plug device 10 is configured to match or substantially match or otherwise at least partially resemble one or more other types of wall finishes, including without limitation, other cement or mortar-based exterior surface, fiber cement siding, composite siding, vinyl siding, veneer, stone (e.g., natural or manmade), brick, cinderblock, other masonry and/or the like. Accordingly, the plug 10 can provide an eloquent and seamless (or substantially seamless) exterior finish to the exterior or exposed surface of the structure in the vicinity of a hole or other opening. This can help conceal, at least partially, the creation of the opening and the existence of the opening with a plug inserted therein.

With reference to FIG. 1 , the plug or insert device 10 can include a cylindrical shape having a first end 12 and a second end 14 at opposite sides or portions of the device 10, e.g., along a longitudinal axis L. A main body portion 30 of the device 10 can extend along such an axis L between the first and second ends. As illustrated in FIG. 1 , the plug device 10 can include a first end surface 22 along the first end 12 and a second end surface 24 along the second end 14. In some arrangements, as shown in FIG. 1 , the first and second end surfaces 22, 24 of the plug device have a circular or substantially circular cross-sectional shape. Such a cross-sectional shape can be configured to extend along an entire length or a substantially entire length of the device 10. In other arrangements, however, the cross-sectional shape of the plug or plug device 10 can be different non-circular, such as, for example, oval, square or rectangular, triangular, other polygonal, irregular and/or the like, as desired or required by a particular application or use.

At least one of the ends surfaces 22, 24 of the plug or insert 10 can include a textured surface. As noted above and discussed in greater detail throughout this application, the textured surface can be configured to match or substantially match or otherwise at least partially resemble one or more other types of wall finishes, including without limitation, other cementitious or mortar-based exterior surface, fiber cement siding, composite siding, vinyl siding, veneer, stone (e.g., natural or manmade), brick, cinderblock, other masonry and/or the like. By way of example, additional embodiments of plug devices 10A, 10B, 10C, 10D having a textured end surface 22 are illustrated in FIGS. 3A to 3D.

With continued reference to the texturized or textured surface 22 on at least one end surface 12, as illustrated in FIGS. 1 and 2A to 2D, can match, substantially match, resemble (e.g., at least partially) one of a variety of surfaces of the adjacent wall or other member W of the building or other structure S. In some embodiments, the surface 22 can be configured to include or resemble one or more of the following types of finishes: a smooth finish, a rough or roughened finish, a popcorn finish, a stucco finish, a shiny finish, a matte finish, a brick finish, a block or other masonry finish, a rock or stone finish, a wood finish, a siding finish, a finish of another natural or synthetic material and/or any other type of finish.

Therefore, in some embodiments, the end surface 22 of the plug device or insert 10 can include a non-planar and/or non-smooth finish. The pattern, shape, height, density of elements and/or other features of the patterning along the textured end surface 22 can be customized in any desired or required manner. For example, as discussed below, in some configurations, the pattern 22 can be created using molds that accurately or approximately match a pattern of known patterns of common or standard exterior finishes (e.g., traditional or roughened stucco, smoot, stucco, rock or stone, brick, block, other masonry, wood or composite siding, etc.).

According to some embodiments, the textured surface 22 includes an uneven or non-smooth surface. The textured surface can include one or more features 26, such as, for example and without limitation, dimples, cavities and/or other recesses, bumps (e.g., smooth or non-smooth), other protrusions, undulations and/or the like. The pattern of such elements (e.g., recesses, protrusions, etc.) 26 can be uniform or non-uniform, as desired or required. Further, any other aspect of the textured surface 22 can be modified in accordance with a desired look and feel. For example, the density, spacing, maximum extent of bumps or other protrusions 26 (e.g., relative to any adjacent features, relative to a plane formed along the distal most end of the features, etc.) can be varied.

The plug devices or inserts 10 can be manufactured to include such surface features. For example, as discussed below, the device 10 can be manufactured using casts, molds and/or other similar processes or technologies. Such molds or other devices can create the desired textured surfaces by having corresponding mold surfaces with the desired non-smooth configuration. For instance, the molds can include a dimpled, roughened and/or surface such that a cementitious or other setting material inserted within the mold cavity or cavities will adopt a corresponding (e.g., mirror image) surface pattern along the textured end surface 22.

In other arrangements, either in lieu of or in addition to utilizing casting or molding technologies, the textured end surface 22 of a plug device can be created during and/or after the manufacture of the device 10. By way of example, the textured features (e.g., bumps, other protrusions, gaps, recesses, etc.) 26 along the end surface 22 can be created by roughening (e.g., scratching, grinding, etc.) the surface. Such roughening activities can be performed while a plug device is curing or otherwise setting in a mold (e.g., along an exposed surface of the mold) and/or after the curing or setting has been completed or substantially completed, as desired or required.

In some embodiment, the non-smooth elements or other elements that help create a textured end surface 26 (e.g., bumps, other protrusions, plateaus, recesses, peaks, valleys, undulations, etc.) can have a uniform and/or consistent shape, height, cross-sectional shape, distribution, spacing, density and/or other properties. See, by way of example, the plug device embodiments illustrated in FIG. 3B. However, in other embodiments, such properties can be non-uniform and/or non-consistent. For example, as illustrated in the embodiments depicted in FIG. 3D, the various bumps or other protrusions (and thus, the areas between such protrusions) along the end surface 22 can vary from one another in one or more manners, such as, shape, size, spacing, distribution and/or the like.

As schematically illustrated in the front perspective view of FIG. 4 and the size view of FIG. 5 , the plug device 10 can include a height or length H and a diameter or other cross-sectional dimension D. In some embodiments, the length or height H (e.g., the distance along the longitudinal axis L in a cylindrically shaped device) can be 1 inch. The distance can be greater or less than 1 inch, as desired or required. For instance, in some embodiments, the length of the device 10 is between 0.5 inches to 2 inches (e.g., 0.5-2, 0.5-0.6, 0.5-0.7, 0.5-0.8, 0.5-1.0, 0.8-1.0, 0.8-1.2, 0.9-1.0, 1.0-1.1, 1.0-1.2, 1.0-1.3, 1.0-1.4, 1.0-1.5, 1.0-1.5, 1.5-2.0 inches, lengths between the foregoing values and ranges, etc.). In other embodiments, however, the length H of the plug devices 10 can be less than 0.5 inches or greater than 2 inches, as desired or required.

With continued reference to the schematic of FIG. 4 , the diameter or other cross-sectional dimension of the plug device 10 can be 0.4 to 1.3 inches (e.g., 0.7, 0.8, 0.9, 0.4-0.7-1.0, 0.7-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.0-1.3 inches, diameters or cross-sectional dimensions between the foregoing values and ranges, etc.). In other embodiments, however, the diameter or other cross-sectional dimension D of the plug device 10 can be less than 0.4 inches (e.g., 0.1, 0.2, 0.3, 0.1-0.2, 0.1-0.2, 0.2-0.3, 0.3-0.4, 0.1-0.4 inches, less than 0.1 inches, etc.) or greater than 1.3 inches (e.g., 1.3-1.5, 1.5-2.0 inches, greater than 2.0 inches, etc.).

Relatedly, the ratio of length H to diameter (or other cross-sectional dimension) D to the plugs or plug devices or inserts 10 can be 1.0:1 to 1.5:1 (e.g., 1.0:1, 1.1:1, 1.2:1, 1.3:1, 1.4:1, 1.5:1, 1.0:1-1.5:1, 1.0:1-1.4:1, 1.0:1-1.3:1, 1.1:1-1.5:1, 1.1:1-1.4:1, 1.1:1-1.3:1, ratios between the foregoing values or ranges, etc.). In other embodiments, the ratio of length H to diameter (or other cross-sectional dimension) D to the plugs or plug devices or inserts 10 is less than 1.0:1 (e.g., 0.8:1-1.0:1, 0.9:1-1.0:1, 0.7:1-1.0:1, 0.5:1-0.7:1, 0.5:1-1.0:1, less than 0.5:1, etc.) or is greater than 1.5:1 (e.g., 1.5:1-1.6:1, 1.6:1-1.7:1, 1.7:1-1.8:1, 1.8:1-1.9:1, 1.9:1-2:1, 2.0:1-2.5:1, greater than 2.5:1, etc.).

As schematically depicted in FIGS. 4 and 5 and discussed throughout this application, at least one end surface 22 of the plug or insert device 10 can include a textured or non-smooth surface. For example, in some arrangements, the end surface 22 comprises a plurality of bumps, protrusions, recesses and/or other surface features 26. The features 26 can be organized in a predictable, uniform distribution and/or orientation (see, e.g., FIG. 3B). In other embodiments, however, any features 26 of the end surface 22 are organized in a random, non-uniform distribution and/or orientation (see, e.g., FIGS. 1, 3B to 3D).

The height of the bumps or other features 26 relative to a base 25, which may be referred to as the relief R1, R2, can be 1 mm to 3 mm (e.g., 1 to 3, 1 to 2, 2 to 3, 1.5 to 2.5, 0 to 1, 0 to 2, 1 to 5, 2 to 5, 0 to 5, 1 to 5, 2 to 5, 0 to 4, 0 to 3 mm, lengths between the foregoing values or ranges, etc.). In other embodiments, the relief R1, R2 is greater than 5 mm, as desired or required. As schematically depicted in FIGS. 4 and 5 , the bumps or other surface features 26 can have two different relief values R1, R2. In other arrangements, the relief R1, R2 can include more than two values (e.g., 3, 4, 5, more than 5, etc.).

According to some embodiments, a plug or insert device 10 (e.g., a cylindrical plug) includes texturing (e.g., bumps, other protrusions, recesses, etc.) 26 along each of its end surfaces 22, 24. The texturing 26 on one end 22 can be different than the texturing on the opposite end 24. For example, the texturing 26 on the end surfaces 22, 24 can vary in type (e.g., types of bumps, other protrusions, recesses, etc.), pattern, density, distribution, uniformity, relief and/or in any other way, as desired or required.

Such embodiments of the plugs or insert devices 10 can offer certain advantages. For instance, a single insert 10 can be reversible to allow it to be used on different types of building surfaces. In some embodiments, a kit is provided that includes a plurality of insert devices 10 having different texturing on each of their end surfaces 22, 24. Such insert devices or plugs 10 can vary from one another, providing a user with a larger number of texturing options to match, substantially match or otherwise resemble the corresponding surface (e.g., exterior surface) of a building or other structure. In other embodiments, a kit can include a plurality of insert devices or plugs 10 with texturing 26 along only one end surface 22, 24. In such kits, the texturing 26 can vary (e.g., in or more manners) to provide the user options when trying to match or approximate the texturing of an adjacent building surface.

As discussed in greater detail below with reference to examples of how the plug devices are handled, installed and/or otherwise used, the plug device 10 can include one or more holes or other openings 28. For example, as shown in FIGS. 1, 4 and 5 , the opening 28 can extend at least partially through the main body portion 30 of the device 10. Such an opening 28 can include a circular cross-sectional shape and can be straight or tapered. In some embodiments, the opening 28 extends about halfway along the main body portion 30 (e.g., in a direction along the longitudinal axis L of the device) and daylights or ends along one of the end surfaces 22, 24. The opening 28 can extend to only one end surface 22, 24 of the device 10. However, in alternative embodiments, the opening 28 extends to both end surfaces 22, 24 (e.g., extends throughout the entire length of the device).

In some arrangements, the opening 28 extends 20% to 80% (e.g., 20 to 80, 30 to 70, 20, 30, 40, 50, 60, 70, 80%, percentages between the foregoing values or ranges, etc.) of the main body portion 30 (e.g., in a direction along the longitudinal axis L of the device). In certain embodiments, the opening 28 extends less than 20% or more than 80% of the main body portion 30 (e.g., in a direction along the longitudinal axis L of the device). The device 10 can include a single opening 28 (e.g., an opening along the center or centerline of the corresponding end surface 22). However, in other embodiments, the quantity, location, size shape, length and/or other details of the opening can be varied, as desired or required.

As discussed in greater detail herein and illustrated in FIG. 7 , a spike or other handling member 200 can be inserted (e.g., at least partially wedged or friction fit) into the opening 28 to allow the device 10 to be handled without having to directly touch the device itself. Accordingly, a user can apply adhesive along the exterior of the main body portion 30 of the device 10 to facilitate the application of an adhesive A along one or more exterior portions of the device. The handling member 200 can be used to insert the plug or insert device 10 into an opening O of a wall or other portion W of a building or other structure S (see, e.g., FIG. 2 ). Once the plug device 10 has been properly inserted within the opening O, the handling member 200 can be separated from the device and discarded or reused.

In some embodiments, the plug devices 10 comprise concrete (e.g., cement, sand, other binders or fillers, color, other additives, etc.). In one configuration, for example, the devices 10 are manufactured from a mix that includes an expansive cementitious material (e.g., expansive cement or concrete), sand and water. Other materials, including other non-shrink and expansive materials (e.g., expansive cementitious materials) can also be used to create a cementitious slurry than can then be used to create the plugs 10 (e.g., in a mold or using some other casting process). Dyes or other coloring components, waterproofing components, other components configured to facilitate in the setting, storage, transport, installation, protection (e.g., against sunlight, salt or other substances, other environmental conditions, etc.), longevity and the like can also be added to the mix. The exact composition of the materials, the ratio of each component and/or other characteristics of the mix or other components can vary as required or required.

In some embodiments, the plugs or insert devices 10 are made using a molding or casting process. For example, a cementitious mix (e.g., the mixes disclosed herein, equivalents thereof, etc.) or other setting or hardening material(s) can be directed into a mold device. As illustrated in FIG. 6A, the mold device 100 can include one or more cavities 120 that extend within a mold body portion 110 to one end (e.g., the top end) of the mold device 100. The cavities 120 can be cylindrical in shape. However, in other embodiments, the cavities 120 are shaped and sized according to the desired or required shape of the plug devices 10 to be formed therein. Therefore, the cross-section shape, diameter or cross-sectional dimension, length and/or portions or characteristics of the cavities 120 can be different than specifically illustrated and/or discussed herein. For example, the cavities 120 can have a non-circular cross-sectional shape, such as oval, square or rectangular, other polygonal, irregular, etc.). The size of the mold device 100 can vary (e.g., in height MH, length, width, etc.) based on, at least in part, the quantity and/or size of the plug devices being formed.

In some embodiments, the mold device 100 comprises one or more rigid, semi-rigid and/or flexible materials. For example, in one arrangement, the mold device comprises silicone rubber. The cavities 120 of the mold device 100 can be formed or otherwise created using one or more technologies or methods. For example, a mold device 100 can be manufactured with the cavities formed or cast in the device (e.g., using a molding or casting process, using three-dimensional printing technologies, etc.). Alternatively, the cavities 120 can be formed from removing material from the mold main body. Such removal can be accomplished using coring devices, laser or other cutting devise and/or any other technology or method.

With reference to FIG. 6B, in some embodiments where a molding device 100 is used to manufacture one or more plug devices 10, the textured end surface 22 of the devices can be formed along the closed, bottom ends 124 of the corresponding cavities 120. In some embodiments, the surface of the closed, bottom end 124 of a cavity 120 can be textured or patterned in accordance with the desired texturing along the end surface 22 of the device 10. For example, the texturing along the bottom end 124 of the cavity 120 can include the mirrored (or corresponding) pattern of the desired texturing along the end surface 22 of the plug device 10.

The texturing or patterning along the bottom ends 124 of the cavities 120 can be formed using one or more technologies or methods. In one embodiment, the mold device 100 is formed by casting or molding the device with one or more cavities 120 that include such texturing or patterning at the time the mold device is manufactured. For example, the texturing or patterning can be created using three-dimensional printing, other printing or forming technologies and/or the like. In other embodiments, positive casting members shaped, sized and otherwise confirmed to match the exterior of the desired plug can be used when molding the mold device 100.

The positive casting members used to create the mold device 100 can be formed using any type of technology, such as, three-dimensional printing, creating the desired casting member with at least some manual contribution, etc. In some embodiments, a positive casting member includes a cylindrical member within one or more components, features and/or the like along one of its end surfaces. In some arrangements, one or more items can be secured to the end surface of the positive casting member to create the desired texturing or patterning. By way of example, such items can include, but are not limited to, one or more of the following: steel or other metallic or rigid bearing, other rigid or semi-rigid manmade items (e.g., plastic pieces, scraps, etc.), rigid or semi-rigid natural materials (e.g., quinoa seeds, other seeds, beans, rice, rock dust, wood chips, pebbles, stones, other plant-based seeds, etc.). Items can be secured to the positive casting member using glues or other adhesives. In some embodiments, one or more coatings and/or other treatments are applied to the positive casting members. In other embodiments, the desired texturing along the end surface of the positive casting member can be created by the removal and/or other manipulation of material and/or by otherwise creating the desired patterning.

Irrespective of how a mold device 100 is manufactured, the geometrical shape of the plug or insert device 10 can closely follow or match the shape of the mold cavity 120 from which it is formed. For example, in some embodiments where the plug 10 is cylindrical, as shown in FIG. 1 , the diameter of the device 10 corresponds to the diameter of the cavity. Likewise, the plug length L corresponds to the depth of the cavity 120. In some embodiments, the size and shape of cavity or cavities 120 of the mold device 100 corresponds to the opening O into which the device 10 will be inserted. In certain configurations, the diameter or cross-sectional dimension of the cavity 120 is identical or slightly smaller (e.g., 0.01% to 5% smaller) than the actual opening O in order to, for example, allow for proper fit-in during the installation. In some embodiments, the size of the plug insert or device 10 and/or the size of the cavity of the mold device in which the device is made are determined by the type and size of drill bit or other coring device that will be used to create the opening O in the building or other structure S.

With continued reference to FIG. 6B, the mold device 100 can include an elongated member 130 within each cavity 120. Such elongated members 130 can be shaped, sized and/or otherwise configured to create the desired opening 28 in the plug device 10. In other words, the elongated members 130 help create the openings 28 in the plug devices 10 during the casting or molding process. The elongated members 130 can be fixedly or removably secured to the main body portion 110 and/or other portion of the mold device 100. The elongated members 130 can include one or more materials, such as, for example, thermoplastics, metals, alloys, wood-based materials, other natural or synthetic materials and/or the like.

In some embodiments, a slurry, mix or other forming, setting, solidifying or hardening material (e.g., a cementitious mix with added water) can be directed into one or more of the cavities of a mold device 100 (e.g., through an open top end 122). Sufficient material can be directed in the cavities 120 to fill the entire cavity (e.g., from the bottom end 124 to the top end 122 of the cavity). Such a volume of material directed within the cavity 120 to completely fill the cavity can be referred to as the filling volume of the cavity. In some embodiments, a volume less than the filling volume is directed into the cavity. For example, this can be done for the purpose of creating shorter plug devices 10 relative to the devices for which the mold device was specifically designed.

The transfer of the cementitious slurry or other filling mix into the mold device 100 can be performed automatically (e.g., using a material transfer device, an injection device, etc.), manually (e.g., with the assistance or contributions of a human) and/or a combination of the foregoing. Once a desired amount of filling material has been directed into the cavities 120 of the mold device, the material can be permitted to set for a desired or required time period. In some embodiments, the formed devices 10 are removed from the cavities 120 of the mold device 100 within one hour (e.g., within 15 minutes, within 30 minutes, within 45 minutes, within 60 minutes, 0 to 10 minutes, 10 to 20 minutes, 20 to 30 minutes, 30 to 40 minutes, 40 to 50 minutes, 50 to 60 minutes, etc.) of the time that the cavities were filled. Depending on the types of materials that were used to form the plug device 10, the devices 10 can be ready for transportation, storage and/or installation 1 day following the time that material was directed into the mold device or the time that the devices 10 were removed from the mold device.

In some embodiments, one or more coatings and/or other treatments are applied to the formed plug devices after removal from the mold device. Such coatings can provide one or more benefits to the finished devices. For example, coatings can assist with enhancing the strength of the devices, protecting against cracking, protecting against damage resulting from exposure to light or other ambient conditions or elements, protecting the devices during storage, transport and/or other activities and/or the like.

As depicted in FIG. 2 and discussed herein, the plug or plug device 10 can be shaped, sized and otherwise configured to be inserted within a hole, opening or other orifice O of a wall or other member W of a building or other structure S. In some arrangements, the plug 10 is inserted within the opening O and secured therein using one or more components, devices or other attachment technologies. For example, one or more adhesives compounds or materials, fasteners (e.g., screws, tabs, etc.) and/or the like can be used to help maintain the plug or insert device 10 in a desired or required orientation within the opening O and thus the corresponding wall or other portion W of the building.

In some embodiments, the plug devices 10 disclosed herein are used to at least partially close or block holes or other openings that are created in walls (e.g., exterior walls or surfaces) of buildings or other structures (e.g., residential, commercial, industrial buildings or other structures). Such openings O can be created for one or more reasons, such as, by way of example, for inspections, to secure one or more components (e.g., scaffolding members, other support or reinforcing members, other removable devices, components or members, etc.) to the building or other structure and/or any other reason or purpose. For instance, an opening can be drilled through an exterior wall of a residential or commercial building to inspect one or more portions behind the wall for possible water intrusion or damage, termite or other pest-induced damage, infestation by rodents and other pests, cracks, earthquake-induced or structural damage, etc.

According to some embodiments, inspections include the passage of one or more scopes, visualization devices or tools, cameras, light sources, material extractors (e.g., for sample collection) and/or the like. For example, in one arrangement, an opening is made within a wall of a building and a borescope is inserted through the opening to inspect for possible water or other damage. Therefore, the hole or other opening O in the structure S (e.g., in the wall of a building) can be sized and shaped to accommodate any tools, instruments or other devices that a user may need to advance or otherwise move into and out of the opening. In some embodiments, the opening is created using a drill bit or any other coring device that may be needed or that is desired for the particular application or use. In some embodiments, the diameter or other cross-sectional shape of the opening O is 0.5 to 1.0 inches (e.g., 0.5, 0.6, 0.7, 0.9, 1.0, 0.5 to 1.0, 0.5 to 0.6, 0.6 to 0.7, 0.7 to 0.8, 0.8 to 0.9, 0.9 to 1.0, 0.7 to 0.9, 0.8 to 1.0, 0.6 to 0.8 inches, diameters between the foregoing ranges or values, etc.). In other arrangements, the diameter or other cross-sectional shape of the opening O is less than 0.5 inches (e.g., 0.01 to 0.1, 0.1 to 0.2, 0.2 to 0.3, 0.3 to 0.4, 0.4 to 0.5, 0.01 to 0.5, 0.1 to 0.5, 0.2 to 0.3 to 0.5, diameters between the foregoing values or ranges, etc.) or greater than 1.0 inches (e.g., 1.1, 1.2, 1.3. 1.4, 1.5, 1 to 1.2, 1 to 1.3, 1 to 1.4, 1 to 1.5, 1.5 to 2, 2 to 3, 3 to 4, 4 to 5, 5 to 6 inches, diameters between the foregoing values or ranges, greater than 6 inches, etc.), as desired or required.

According to some embodiments, drilling or coring through a wall of a structure comprises drilling through an exterior stucco wall or other exterior surface. In some embodiments, as illustrated in FIG. 8A, drilling or coring through a wall W includes compromising and/or advancing past (e.g., extending the opening through), at least partially, wire lath and/or other internal wall components E.

After the opening O has been created through the targeted wall or other member of the building or other structure S, the necessary steps can be taken. For example, one or more borescopes, other types of scopes, cameras, other visualization devices, illumination devices, material retrieving devices, other tools or instruments, connection members (e.g., for scaffolding and similar systems that need to be at least temporarily secured to the structure, etc.) and/or the like can be passed into and out of the opening O. In some embodiments, for example, a borescope is passed through the opening O to inspect for possible water damage, terminate damage and/or any other potential issue.

Once the necessary procedures and activities have been completed, a plug device 10 in accordance with any one of the embodiments disclosed herein can be inserted within the opening O to close the opening. For example, as illustrated schematically in FIG. 2 , a concrete plug or insert device 10 can be inserted and secured within the opening. As discussed in greater detail herein, the device 10 can be secured to the wall W and/or any other portion of the building or other structure S using glue or other adhesives, grout, other materials, fasteners and/or any other type of connection device, system, method or technology, as desired or required.

In some embodiments, once secured to the building or other structure, the exterior surface of the plug device 10 (e.g., the end surface 22) is configured to be flush or substantially flush with the adjacent exterior surfaces of the wall W. In other embodiments, once secured to the building or other structure, the exterior surface of the plug device 10 (e.g., the end surface 22) is configured to be recessed or proud relative to the adjacent exterior surfaces of the wall W, as desired required. For example, in one arrangement, the plug device 10 can be secured to the wall W such that it is recessed to the adjacent portions of the wall W. Accordingly, in such configurations, additional grout or other material (e.g., a relatively thin layer of grout or similar material) can be used to fill in the recess and make that portion of the wall flush or substantially flush.

As illustrated in FIG. 7 , a handling device 200 can be secured to the plug device 10 to facilitate the manipulation and/or securement of the device 10 within a desired wall opening O. In some embodiments, the handling device 200 is sized, shaped and/or otherwise adapted to be positioned within and at least temporarily secure to one or more openings 28 of the plug device 10. Such handling devices 200 can advantageously permit a user to handle the plug or insert device 10 without physically (e.g., via direct contact) contacting the device 10. Accordingly, a user can apply one or more adhesives to one or more exterior portions of the device 10 (e.g., the exterior of the device along at least one end of the main body portion of the device). The handling device 200 can be configured to withstand the weight as well as other forces and moments that may be exerted upon the device 10, and thus the handling device 200, while the plug device 10 is inserted into and advanced within the opening O.

According to some embodiments, the handling device 200 is configured to secure to the hole or opening 28 of the plug device 10 using a friction fit or press fit connection. However, in other arrangements, the handling device 200 is configured to secured (e.g., removably) to the plug device 10 using one or more other securement technologies or methods, such as, for example, threaded connection, other releasable locks or similar features, adhesives that are configured for compromise and detachment after a particular time period or after a particular occurrence (e.g., temperature change, light activation, additional of a chemical or other material, etc.).

In some embodiments, the handling device 200 comprises one or more rigid or semi-rigid materials, such as, for example, thermoplastics, metals, alloys, wood, wood or paper-based materials, composites, other natural or synthetic materials and/or the like.

With continued reference to FIG. 7 , when the user is ready to secure the plug device 10 within a targeted opening O (e.g., a drilled hole through a wall of a building for inspection purposes), one or more exterior portions of the device can be coated with an adhesive. In the illustrated embodiment, adhesive is applied to only a portion of the main body portion of the device 10 (e.g., the portion denoted by cross-hatched area A). Alternatively, all or substantially all of the exterior surface of the plug device's main body portion is coated with an adhesive. In some embodiments, a length of 0% to 25% (e.g., 0 to 25, 0 to 10, 10 to 20, 10 to 25%, percentages between the foregoing ranges, etc.) along the longitudinal axis of the device is configured to receive the application of an adhesive. In other embodiments, a length of greater than 25% (e.g., 25 to 50, 50 to 75, 75 to 100, 25 to 75, 25 to 100, 50 to 100%, percentages between the foregoing ranges, etc.) along the longitudinal axis of the device is configured to receive the application of an adhesive, as desired or required.

Once the insert or plug device 10 has been coated with a desired or required amount of adhesive, the user can advance the device 10 within the opening O to secure the device to the wall or other portion of the building or structure. This can be accomplished with the assistance of a handling device 200 secured within an opening 28 of the device 10, as described herein. However, the use of such a handling device or member 200 is not required.

According to some embodiments, the adhesive that is applied to the exterior surfaces of the plug device 10 comprises a curable adhesive. For the example, adhesive can include an adhesive that is curable in the presence or application of ultraviolet (UV) light, another light source, heat (or a cooling effect or heat removal), another energy source, chemicals or other materials, etc. The application of such energy (e.g., UV light) can accelerate the sealing time of the adhesive, thereby speeding up the process of securing the plug device 10 to the wall W or other surface of the structure. The application of light or other energy/material source can be performed using one or more separate devices or system (e.g., a handheld UV light source, a heat source, a fan or other fluid transfer device, etc.), as desired or required for a particular application or use.

Once the plug device 10 has been secured to the structure (e.g., the wall of a building), the user can prime and/or paint the outside of the device 10 and/or adjacent portions of the wall W. In some embodiments, the process of making an opening O in a wall, conducting the necessary activity (e.g., inspection using a borescope or other device), closing the opening O (e.g., by inserting and securing a plug device 10 within the opening) and performing any finishing steps (e.g., priming, painting, grouting, etc.) can be accomplished on a single visit to the structure. In some embodiments, in such arrangements, the need to return to the site for a separate procedure and/or a different day are eliminated. In some embodiments, all the necessary steps mentioned above can be advantageously performed within one day (e.g., within 1, 2, 3, 4, 5, 6, 7, 8 hours, less than 1 hour (e.g., 0 to 15, 15 to 30, 30 to 45, 45 to 60 minutes, times between the foregoing ranges, etc.), 8 to 10, 10 to 12, 12 to 18, 18 to 24, 8 to 24, 0 to 24, 2 to 24, 4 to 24, 6 to 24, 8 to 24 hours, times between the foregoing values or ranges, etc.).

FIGS. 8A and 8B illustrate different views of one embodiment of a plug device 10 inserted and secured within an opening O of a wall or other portion W of a building or other structure S. As shown, the plug device 10 has been inserted within the opening O and secured thereto using an adhesive A. As discussed herein, the adhesive A can be applied to only a portion of the outside surface of the plug device 10 (e.g., along the textured end or exposed end 22 of the device 10). However, in other arrangements, adhesive can be applied to more or fewer portions of the device and/or along different portions of the device 10, as desired or required. As also depicted, the texturing or patterning 26 along the end surface 22 of the device 10 can be configured to match or substantially match the texturing or patterning of the adjacent portions of the wall W. Further, the end surface 22 of the device 10 can be flush or substantially flush with the adjacent portions of the wall.

In some embodiments, there is a gap or clearance provided between the outside of the plug device 10 and the interior of the opening O. For example, the size of the gap or clearance G can be 0 to 5 mm (e.g., 0 to 0.1, 0.1 to 0.2, 0.2 to 0.3, 0.3 to 0.4, 0.4 to 0.5, 0.5 to 0.6 to 0.7, 0.7 to 0.8, 0.8 to 0.9, 0.9 to 1, 1 to 1.5, 1.5 to 2, 2 to 2.5, 2.5 to 3, 3 to 3.5, 3.5 to 4, 4 to 4.5, 4.5 to 5 mm, values between the foregoing ranges, etc.). In other embodiments, the gap or clearance G is greater than 5 mm, as desired or required. In some embodiments, the size of the gap or clearance G is 0 to 5% (e.g., 0 to 0.1, 0.1 to 0.2, 0.2 to 0.3, 0.3 to 0.4, 0.4 to 0.5, to 0.6, 0.6 to 0.7, 0.7 to 0.8, 0.8 to 0.9, 0.9 to 1, 1 to 1.5, 1.5 to 2, 2 to 2.5, 2.5 to 3, 3 to 3.5, 3.5 to 4, 4 to 4.5, 4.5 to 5%, percentages between the foregoing ranges, etc.) of the diameter or cross-sectional dimension of the plug device 10 and/or the opening O.

The systems, apparatuses, devices and/or other articles disclosed herein may be manufactured or otherwise formed through any suitable means. The various methods and techniques described above provide a number of ways to carry out the disclosed inventions. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods may be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.

Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments disclosed herein. Similarly, the various features and steps discussed above, as well as other known equivalents for each such feature or step, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein. Additionally, the methods which are described and illustrated herein are not limited to the exact sequence of acts described, nor are they necessarily limited to the practice of all of the acts set forth. Other sequences of events or acts, or less than all of the events, or simultaneous occurrence of the events, may be utilized in practicing the embodiments of the inventions disclosed herein.

Although several embodiments and examples are disclosed herein, the present application extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and modifications and equivalents thereof. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.

While the embodiments disclosed herein are susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the inventions are not to be limited to the particular forms or methods disclosed, but, to the contrary, the inventions are to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various embodiments described and the appended claims. Any methods disclosed herein need not be performed in the order recited. The methods disclosed herein include certain actions taken by a practitioner; however, they can also include any third-party instruction of those actions, either expressly or by implication. The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “about” or “approximately” include the recited numbers. For example, “about 10 mm” includes “10 mm.” Terms or phrases preceded by a term such as “substantially” include the recited term or phrase. For example, “substantially parallel” includes “parallel.” 

What is claimed is:
 1. A plug for use in closing an opening along an external surface of a structure, the plug comprising: a main body including a first end to a second end, the main body extending from the first end to the second end along a longitudinal axis; a first surface located along the first end of the main body, wherein the first surface is perpendicular or substantially perpendicular to the longitudinal axis; a second surface located along the second end of the main body, wherein the second surface is perpendicular or substantially perpendicular to the longitudinal axis; and at least one opening or feature along the first surface, wherein the first opening or feature is configured to permit a user to manipulate the plug without directly contacting the plug; wherein the first surface comprising a non-smooth finish; wherein the plug comprises a setting or a hardening material; wherein the plug is configured to be placed within a corresponding opening of a wall or other structural component of a building; and wherein the plug is configured to remain fixed within the corresponding opening using at least one adhesive.
 2. The plug of claim 1, wherein the non-smooth finish of the first surface comprises a textured surface; wherein the setting or the hardening material comprises a cement, another binder, a concrete and/or another cementitious component; and wherein the main body comprises a cylindrical shape.
 3. The plug of claim 1, wherein the non-smooth finish of the first surface comprises a textured surface.
 4. The plug of claim 3, wherein the textured surface comprises a stucco exterior finish.
 5. The plug of claim 3, wherein the textured surface comprises a plurality of bumps, other protrusions and/or recesses.
 6. The plug of claim 1, wherein the setting or the hardening material comprises a cement, another binder, a concrete and/or another cementitious component.
 7. The plug of claim 1, wherein the main body comprises a cylindrical shape.
 8. The plug of claim 1, wherein the at least one adhesive is positioned along at least one exterior surface of the plug.
 9. The plug of claim 8, wherein the at least one exterior surface of the plug that received the adhesive is located along an exterior of the main body.
 10. The plug of claim 1, wherein the plug is manufactured using a casting process.
 11. A method of closing an opening in a wall or other member of a building or other structure, the method comprising: inserting a plug device within the opening, wherein the plug device is shaped, sized and otherwise configured to be positioned within the opening; and securing the plug device within the opening using at least one securement technology; wherein an exposed surface of the plug device is configured to match or substantially match a surface of the wall or other member of the building or other structure immediately adjacent to the opening.
 12. The method of claim 11, wherein the at least one securement technology comprises an adhesive positioned along an exterior surface of the plug device.
 13. The method of claim 11, wherein the opening in the wall or other member is created using a drill or other coring device.
 14. The method of claim 11, wherein the opening in the wall or other member is 0.5 to 2 inches in diameter, and wherein a diameter of the plug device is between 0.5 to 2 inches.
 15. The method of claim 11, wherein the opening in the wall or other member is configured to allow for a scope or other visualization tool or instrument to be positioned therethrough.
 16. The method of claim 11, wherein the opening in the wall or other member is used for inspection purposes.
 17. The method of claim 11, wherein a clearance exists between the outside of the plug device and an interior of the opening in the wall or other member.
 18. The method of claim 11, wherein the plug device in inserted into the opening using a handling device.
 19. The method of claim 18, wherein the handling device comprises an elongated member that is configured to removably secure to a hole along a surface of the plug device.
 20. The method of claim 11, wherein the plug device comprises a cement, a concrete or another cementitious material. 